Outboard Insulation Mounting System

ABSTRACT

An Outboard Insulation Mounting System and products for the purpose of providing a continuously insulated (CI) wall utilizing a dual nailing flanged stud, sub-girts with multiple aligned flanges and holes, a fastener for penetrating the multiple surfaces of the stud and sub-girt for the purpose of transferring cantilevered stresses to the screw from more than one direction, compounding the load capacity of the cantilevered screw. Rigid insulation installed between the studs and sub-girts may be compressed and assist with the load capacity of the cantilevered fasteners, as well as being supported by these fasteners along with any attached façade panels or façade systems to the sub-girts.

CROSS REFERENCES TO RELATED APPLICATIONS

The present application claims the benefit of U.S. Provisional Patent Application Ser. No. 62/967,042 filed Jan. 29, 2020.

BACKGROUND OF THE INVENTION

The present invention relates to an Outboard Insulation Mounting System that utilizes dual walled studs and dual walled exterior girts that require less penetrations through the wall assembly and weather barrier, they utilize the strength of the multi-attachment points on the fasteners to support loads outside of and perpendicular to the stud on building interiors and exteriors, they can eliminate the use of structural clips and isolators that normally support exterior girts, they will only allow screws to penetrate the insulation meeting the 2019 ASHRAE 90.1 of Continuous Insulation, they provide anti-reversing of fasteners, and will provide for less thermal, vibration, water, air and moisture transfer to the building.

In the past there have been a good number of ways that insulation can be installed on a building including friction fitting the insulation batts between thermal clips and then screwing them to the wall with long screws and plastic or metal washers in a pre-designated pattern, each of which will penetrate the weather barrier and create a potential location for leakage to the building substrate, as well as providing a thermal and vibration bridge from the exterior to the interior of the building. Other options include a stick-on pins that the insulation is mounted over, and then lock washers of various types are placed over the pins so that they don't back off of the pin keeping the insulation in place, however this process is very time consuming and unpredictable regarding adhesion and is therefore not allowed by major insulation manufacturers. There are also continuous sub-girts used, but they transfer too much thermal energy and vibration through to the substrate, and they by definition and application are then not able to be considered ‘continuous insulation’.

The present invention provides novel and useful products and methods for mounting insulation to the exterior of buildings that utilize continuous exterior insulation principles in order to provide for faster installation of the insulation, minimize penetrations through the weather barrier, minimize materials used, and provide attachment options to the building for various façade types and conditions making a notable advancement in this field.

SUMMARY OF THE INVENTION

In accordance with the present application, a novel and useful Outboard Insulation Mounting System products and methods of installation are herein provided that include specially shaped or modified stud(s) and special sub-girts. There will be variations of the same concepts such as vertical and horizontal sub-girt shapes.

The steel studs will have at least one additional leg that will provide at least one additional penetration location for the mounting screws in order to be able to cantilever loads from these fasteners. The additional leg on the stud or girt may be made as one-piece via roll forming process or as an added attachment to the stud. The steel stud may be fabricated and formed of a material such as galvanized steel sheet metal or coil on a roll forming machine with various in-line punches, or it may be made with multiple machines such as a turret press and brake press. If the additional leg is to be an attachment it may be attached to any stud using any mechanical means such as a spot welding, self drilling screws, rivets, clinching, etc. If part of the one-piece steel stud, the additional leg may be bent more easily by scoring the metal or using punched holes or slots to cause it to bend easier than bends without them. The steel studs will have all of the normal holes, slots, bends, indentations and other features commonly found in presently used studs which will be used for running conduits, pipes, tubes, insulation and other mechanisms through or in, as well as to prevent transfer of vibration.

The sub-girts will be fabricated and formed of a material such as galvanized steel sheet metal or coil on a roll forming machine with various in-line punches, or it may be made with multiple machines such as a turret press and brake press. The sub-girts will have holes that allow for the special screw to pass through them in-line when the sub-girt is positioned adjacent to the insulation. Having multiple holes for the special screw to attach through adds structural strength and minimized deflection (or sag) of the sub-girt by minimizing bending/deformation of the fastener when a load is applied to the sub-girt. The sub-girts may have protrusions coming from them that penetrate the insulation or have other mechanical fasteners attach to them that further hold the insulation in place such as formed wire shapes (as disclosed in a previous patent application). The sub-girts may have vertical, horizontal, diagonal, rounded, radiused, and/or other shaped surfaces to attach additional clips, sub-girts or other materials to allow for planing, leveling and plumbing of the substrate for installation of a façade system, or to help hold in position the insulation material(s). The sub-girts will have a surface that contacts the insulation in such a way as to provide a certain amount of contact area so that the insulation is not easily moved, deformed or crushed, although the insulation may be compressed. By preventing movement of the sub-girts air gaps will be less likely to open up in the insulation at the screw locations allowing air, water, moisture, vibration and thermal transfer to more easily access the substrate. The screw material type, size and quantity will determine the amount of load that can be applied before the fasteners begin to bend.

The spacers may be made of a rigid material such as plastic and formed in a process such as injection molding. The spacers will help prevent backing-out (or reversing) of the special screws, provide a structural bridge between flanges of the sub-girts, and be shaped to fit the sub-girts as required.

The insulation may be materials such as foam board or mineral wool by manufacturers such as Owens Corning and ROCKWOOL. The rigidity of the insulation will help prevent movement of the sub-girts by way of the insulation not easily compressing when the surface of the sub-girts presses against it.

It may be apparent that novel and useful Outboard Insulation Mounting System products and methods have been hereinabove described which work and are used in a manner not consistent with conventional products and methods.

It is therefore an object of the present application to provide an Outboard Insulation Mounting System that provides a stud with multiple walls for a fastener to penetrate in order to help prevent the bending or movement of the fastener, as well as to prevent deformation of the stud material that would happen with only one point of connection.

Another object of the present application is to provide an Outboard Insulation Mounting System that allows for the additional wall to be made as part of the stud during normal fabrication and forming, or as an attachment to any existing stud.

Another object of the present application is to provide an Outboard Insulation Mounting System that allows for a stud being fabricated and formed as one piece and to have an anti-reversal “tab” or means to prevent a formed flange of the stud from moving once it's formed, locking it into place permanently.

Another object of the present application is to provide an Outboard Insulation Mounting System that allows for the stud of the present invention to have both ends with double walls to support cantilevered loads both inside and outside.

Another object of the present application is to provide an Outboard Insulation Mounting System that provides a screw that, by being positioned between multiple contact points of the stud and/or sub-girt, accepts loads that would normally cause the screw, stud and/or sub-girt to bend or otherwise deform because of only 2 points of contact.

Another object of the present application is to provide an Outboard Insulation Mounting System that provides a screw with threads that can enter, tap and fasten to more than one mounting surface.

Another object of the present application is to provide an Outboard Insulation Mounting System that provides a screw that takes onto itself tensive, compressive, bending, shear and other forces that may otherwise be exerted to the sub-girt and/or stud, when used with either the stud and/or sub-girt of this application.

Another object of the present application is to provide an Outboard Insulation Mounting System with a sub-girt with multiple bends that allow for more than one hole to become aligned once formed so that a screw can pass through the holes simultaneously and in a specific direction.

Another object of the present application is to provide an Outboard Insulation Mounting System with a sub-girt with multiple levels such as two for the fastener to pass through and a third that's higher that allows other girts to attach to it without contacting those fasteners.

Another object of the present application is to provide an Outboard Insulation Mounting System with a sub-girt that allows for vertical, horizontal, diagonal placement, and otherwise shaped to allow for additional materials to attach to it such as other sub-girts and insulation hangers, and allowing for adjustability of the final surface that a façade system may be mounted to.

Another object of the present application is to provide an Outboard Insulation Mounting System that has a sub-girt with multiple holes for the screw to pass through to help prevent deformation of the sub-girt material when loads are placed onto the sub-girt.

Another object of the present application is to provide an Outboard Insulation Mounting System with a sub-girt with one or more surfaces providing attachment for façade panels, including resting directly on or adjacent to the sub-girt, or to an attachment that is connected to the sub-girt.

Another object of the present application is to provide an Outboard Insulation Mounting System with a double walled sub-girt that may be used to cantilever screws independently of a double walled stud.

Another object of the present application is to provide an Outboard Insulation Mounting System with a spacer that is shaped and positioned into the sub-girt to help prevent the flanges of the sub-girt from moving when loads are applied to them.

Another object of the present application is to provide an Outboard Insulation Mounting System with a spacer that is shaped to help prevent the screw from backing-out of the stud once it's installed by ‘grabbing’ the threads or ‘shoulder’ of the screw by friction so that they don't easily move.

Another object of the present application is to provide an Outboard Insulation Mounting System with a spacer that is not easily crushed or deformed when force is placed against it.

Another object of the present application is to provide an Outboard Insulation Mounting System with a spacer that, once attached to the sub-girt in a specific location, will not easily move from that location until a screw can be installed through the holes of the sub-girt and the hole(s) in the spacer for permanent fixing.

Another object of the present application is to provide an Outboard Insulation Mounting System with a spacer that may be used as a thermal break around the screw to help prevent thermal energy from passing through the screw and to the substrate by partly filling the holes with it's plastic embodiment.

Another object of the present application is to provide an Outboard Insulation Mounting System that provides for rigid insulation to be used to help prevent movement of the sub-girt that has been attached to the studs via screws, having a surface that does not easily crush or deform under various types of pressure, and the amount of pressure required to crush or deform the insulation being based, in part, on the amount of surface area the sub-girt provides adjacent to the insulation.

Another object of the present application is to provide an Outboard Insulation Mounting System that allows for longer insulation batts or rolls to be used which will provide less manufacturing and faster installation onto walls.

Another object of the present application is to provide an Outboard Insulation Mounting System that allows the insulation to be installed continuously without any materials penetrating or otherwise positioned between the insulation except for the screws.

Another object of the present application is to provide an Outboard Insulation Mounting System that provides a way to mount façade panels and façade systems directly or indirectly to the components of this invention.

The invention possesses other objects or advantages especially as concerns particular characteristics and features thereof which will become apparent as the specification continues.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is a 2D plan cross section view of the preferred embodiments of the stud and sub-girt of the present application showing a vertically positioned sub-girt shown in a wall assembly not including interior insulation or interior drywall.

FIG. 2 is a 2D plan cross section view of alternate embodiment of an assembled stud of the present invention working similarly to that of FIG. 1.

FIG. 3 is a 3D elevation isometric cross section view of a horizontal sub-girt mounted with the preferred stud of the present invention sliced so that some of it is missing to show the details better.

For a better understanding of the invention of this application, reference is made to the following detailed description of the preferred embodiments thereof which should be referenced to the prior described drawings.

DETAILED DESCRIPTION OF THE INVENTION

Various aspects of the present application will evolve from the following detailed description of the preferred embodiments thereof which should be taken in conjunction with the prior described drawings.

Embodiments of the invention are identified by an upper case letter with an additional upper case letter of the same kind for a variation of the embodiment. Elements of the invention are identified by reference character 10.

With reference to FIG. 1, it can be seen that the preferred embodiments of vertical sub-girt B and stud A are shown in an wall assembly. Stud A is comprised of support 10, substantially perpendicular to return 12, which is substantially perpendicular to web 14. Protrusion 16 is a punched-and-formed tab that is made in a pattern that leaves opening 18 in the web. Web 14 is substantially perpendicular to return 20 which is substantially perpendicular to support 22 which is substantially perpendicular to double return 26. Support 22 may a half-circular shape beginning at return 20 and ending at Double return 26. Bend 24 may be scored or have hole slots (not shown) and made with punches and dies (not shown) as described to ease the bending procedure as a final bend, although scores or slots (not shown) may be located at any bend for this purpose. Sheathing 54 is adjacent to stud A return 20, weather barrier 52 is adjacent to sheathing 54, insulation 50 is adjacent to weather barrier 52, and Girt B is adjacent or compressing, insulation 50. Sub-girt B is shown having upper arm 40, and lower arm 34 having holes 30 made with punch and dies (not shown) and holes being in alignment with each other to allow fastener 48 to enter and be directionally positioned through them. Support 32 is diagonally positioned between upper arm 40 and lower arm 34 to provide the separation between them. Support 36 is substantially perpendicular to lower arm 34 and has mounting surface 38 to allow for mechanical fasteners. Adjustable girt D has mounting surface 46 on leg 44 to allow mechanical fasteners (not shown) to permanently connect to sub-girt B to it at mounting surface 38 of support 36. Mounting arm 42 is used to mount façade systems (not shown) or façade support systems (not shown) directly to it. Spacer C is shaped to match sub-girt B as shown, and has through hole 56 extending it's full height to prevent upper arm 40 from compressing towards lower arm 34 when screw 48 is installed, as well as to provide friction on screw 48 to prevent it from backing out over time. Fastener 48 has self-drilling end 28 which penetrates through holes 30 of Girt B, insulation 50, weather barrier 52, sheathing 54, and drills to make it's own holes (not shown) in return 20 and double return 26 so that screw 48 is prevented from flexing (not shown) from self drilling end 28 at stud A or from the beginning at Girt B, effectively compounding it's load supporting strength because the bend directions would oppose each other.

Referring now to FIG. 2, it is identical to FIG. 1 with the exception that stud AA is shown to have an attached angle E which provides double support 58 which is substantially perpendicular to arm 60 which mounts to web 62 via mechanical fasteners (not shown).

Last, referring to FIG. 3, stud A is shown in a lengthwise cross section so that some parts of the embodiment are not shown, allowing other components to be shown more fully. Not shown on stud A are support 10, support 24 and bend 24. Protrusion 16 is shown from a different angle with the shadowed portion behind it being opening 18. Two fasteners 48 attach horizontal girt F to stud A, one on each end of the width of horizontal girt F. Horizontal girt F consists of two double returns 64, two supports 68 and web 72. Upper holes 66 are found in double returns 64 while lower holes 70 are found in web 72. Upper holes 66 and lower holes 70 are in alignment with each other and control the direction of screws 48 when inserted. Each side of horizontal girt F is independently adjustable (not shown).

While the foregoing embodiments of the application have been set forth in considerable particularity for the purposes of making a complete disclosure of the invention, it may be apparent to those of skill in the art that numerous changes may be made in such details without departing from the spirit and principles of the application. Additionally, combinations and interchangeability or inter-use of components and embodiments should be considered apparent to the spirit and principles of the application, and in which all terms are meant in their broadest, reasonable sense unless otherwise indicated. Any headings utilized within the description are for convenience only and have no legal or limiting effect. 

What is claimed is:
 1. A system and devices for attaching insulation to a building, comprising a roll formed stud having: a first support leg, said first support leg terminating in a first return for contacting sheathing; a web, said web being contiguous with said support leg and extending from said first return; a second return, said second return being contiguous with said first return, and extending from said web; a second support leg, said second support leg being contiguous with said web; a double return, said double return being contiguous with and in dose proximity to said second return, and said double return terminating at said web.
 2. The device of claim 1 in which said second return, said second support, and said double return are configured on both terminations of said web, replacing said first support and said first return.
 3. The device of claim 1 which further comprises at least one tab, said tab extending from said web and angularly positioned against said double return to prevent said double return from further movement.
 4. The device of claim 1 which further comprises a bend, said bend having holes, and said holes being configured linearly to allow easy forming of said bend.
 5. The device of claim 1 which further comprises a fastener, said fastener penetrating said second return and said double return in sequence so that said fastener is positionally fixed.
 6. The device of claim 1 which further comprises at least one aperture in the web.
 7. The device of claim 1 comprising said second return and said double return creating an anti-rotation means for said fastener via friction from two locations and counteracting forces between said second return and double return caused from the insertion of said fastener into them.
 8. A formed sub-girt having: a first return, said first return terminating in an arm, said arm extending from said first return; a second return, said second return contiguous with said first return and extending from said arm; a support leg, said support leg extending from said second return.
 9. The device of claim 2 in which said support leg variably attaches to an adjustable girt via a first fastener.
 10. The device of claim 2 which further comprises holes, said holes aligned within said first return and said second return, and said alignment substantially perpendicular to said first return and said second return, and said holes for placement of a second fastener.
 11. The device of claim 2 which further comprises a spacer, said spacer fixed between said first return and said second return, said spacer creating anti-rotation of said second fastener via friction
 12. The device of claim 2 wherein said second fastener is positionally fixed between said first return and said second return.
 13. A system of attachment with said stud of claim 1 in combination with said sub-girt of claim 2 having: said second fastener of claim 2 inserted into said holes of said sub-girt providing a first positional fixing within said holes of said sub-girt, wherein said second fastener further extends and penetrates through said second return and said double return of said stud providing a second positional fixing.
 14. The device of claim 3 in which first positional fixing of claim 5 and second positional fixing of claim 12 work together to further positionally fix said second fastener, wherein contradicting forces on said stud and said sub-girt cause said second fastener to try to bend in opposite directions, compounding a cantilevered load capacity.
 15. The device of claim 3 in which first anti-rotation of claim 11 and second anti-rotation of claim 7 work together to prevent said second fastener rotation. 